Method of making animated figure toys having embedded connector means and a thickened area



April 29, 1969 j w N ET AL 3,440,714

METHOD OF MAKING ANIMATED FIGURE TOYS HAVING EMBEDDED CONNECTOR MEANSAND A THICKENED AREA Filed June 17, 1966 Sheet of 6 INVENTORS JZ/M w.Rmw

3,440,714 E TOYS HAVING EMBEDDED CONNECTOR Sheet April 29, 1969 J. wRYAN ET AL METHOD OF MAKING ANIMATED FIGUR MEANS AND A THICKENED AREA1966 Home .1. Mir

Filed June 17,

3,440,714 METHOD OF MAKING ANIMATED FIGURE TOYS HAVING EMBEDDEDCONNECTOR April 29, 1969 j w RYAN ET AL MEANS AND A THICKENED AREA FiledJune 17, 1966 Sheet 3 of 6 WMARQMQ 3 Q3 RE D 5 2r mum I? Z M F 3 D f Apr29, 1969 w RYAN ET AL METHQD OF MAKING ANIMATED FIGURE TOYS'HAVINGEMBEDDED CONNECTOR MEANS AND A THIGKENED AREA Filed June 17, 1966 Sheet4 of 5 Aprfi 29, 1969 J. W. RYAN ET AL 3,440,714

METHOD OF MAKING ANIMATED FIGURE TOYS HAVING EMBEDDED CONNECTOR MEANSAND A THICKENED AREA Filed June 17, 1966 Sheet 5 of 6 4i i? f0 floj 15 U342 4 3% 3&0 34 6 gzp/ W; 212

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METHOD OF MAKING ANIMATED FIGURE TOYS HAVING EMBEDDED CONNECTOR MEANSAND A THICKENED AREA Filed June 17 1966 Sheet Ava! rues fla /72D A177/77 United States Patent O U.S. Cl. 29-526 6 Claims ABSTRACT OF THEDISCLOSURE A method of making animated figure toys having a unitary,hollow plastic portion that is for-med with areas of different hardnessand flexibility with one of the areas being formed from a thermoplasticmaterial to which an animator means may be connected by heat-softeningthe material and embedding at least a portion of a connector meanstherein.

In the toy industry, the use of soft, flexible plastic materials, suchas plastisol, and improved molding techniques make it possible toproduce toy figures having face portions which are movable in a mannerto closely simulate the movement of the face portion of a human being oran animal. While generally satisfactory for the face portion of the toyfigure, such materials and molding techniques have the disadvantage thatthe head portion of the toy is also soft and flexible.

Another disadvantage resides in the fact that the means employed toimpart movement to the face portion is sometimes rather difficult toattach to the soft plactic material satisfactorily.

In view of the foregoing factors and conditions characteristic of figuretoys having soft, flexible plastic face portions, it is a primary objectof the present invention to provide a new and useful apparatus for andmethod of making animated figure toys not subject to the disadvantagesenumerated above and including method steps for producing a figure toyhaving a soft, flexible face portion and a skull portion which is harderand less flexible than the face portion.

Another object of the present invention is to provide a new and usefulapparatus for and a method of connecting animating means to a soft,flexible portion of a figure toy.

Yet another object of the present invention is to provide a new anduseful method for molding a hollow plastic article.

Still another object of the present invention is to provide a method ofmolding a unitary, hollow plastic article having portions of varyinghardness.

A further object of the present invention is to provide a method ofmolding a unitary, hollow plastic article having portions of varyingthickness.

A still further object of the present invention is to provide a methodof molding a hollow, unitary, plastic article, such as the head of a toyfigure, wherein the face portion of the head is softer and more flexiblethan the balance thereof, to thereby enable the face portion to bemovable in a manner to closely simulate the movement of the face portionof a human being, or an animal.

Another object of the present invention is to provide a new and usefulapparatus for and a method of connecting animator means to the soft,flexible plastic portion of a figure toy by embedding connector means inthe thermoplastic material by heat-softening the material while pressureis applied to the connector means to embed it in the material.

According to one of the methods of the instant inven ICC tion, aslush-type mold is first filled with a first liquifled plastisol of apredetermined composition. The filled mold is then immersed in a hotbath or otherwise heated to a predetermined temperature and for apredetermined time period to effect an initial cure of the plastisoltherewithin. Thereafter, the mold is drained to leave a jelled layer ofthe plastisol on the inner surface thereof. The mold is then partiallyrefilled with a similar second plastisol which is harder than the firstplastisol, and owing to a predetermined orientation of the mold, thesecond plastisol composition covers only a predetermined portion of thejellcoated mold. The partially filled mold then is subjected to a secondcuring step by immersing it in a hot bath or otherwise heating it to apredetermined temperature and for a predetermined time period. After thedesired partial curing of the second plastisol composition in the mold,the mold is drained to leave a jelled layer of the second plastisol onthe predetermined portion of the mold. Finally, the first and secondplastisol layers are finally cured and cooled, and the molded, unitary,hollow article is removed from the mold in any suitable manner. Themolded, unitary article comprises a first portion formed of the layer ofthe first plastisol, and a second predetermined portion formed of thelayer of the first plastisol and the harder layer of the secondplastisol, the second portion thus being harder and less flexible thanthe first portion.

Animator means may then be connected to the first portion by employingthe apparatus of the present invention to place a connector means in anelectrical circuit for heating the connector means by resistance-heatingtechniques. The connector means is pressed into the thermoplasticmaterial during the supply of current to the connector means for meltingthe material to embed the connector means therein. The material is thencooled and resolidified around the embedded portion after which animatormeans may be connected to the connector means. Many thermoplasticmaterials serve this purpose very well. Although a vinyl composition ispresently preferred, it is to be understood that the connector means maybe used in accordance with the present invention in combination with anymaterial that will melt and then resolidify around the connector means.

The features of the present invention which are believed to be novel areset forth with particularity in the appended claims. The presentinvention, both as to its organization and manner of operation, togetherwith further objects and advantages thereof, may best be understood byreference to the following description, taken in connection with theaccompanying drawings in which like reference characters refer to likeelements in its several views.

IN THE DRAWINGS FIGURES 1 through 3 are schematic views showing some ofthe steps of a preferred method of molding a hollow plastic article inaccordance with the teachings of the instant invention;

FIGURE 4 is a side elevational view in section of a hollow article, suchas a dolls head, formed in accordance with the method steps shown inFIGURES 1 through 3;

FIGURE 5 is a view similar to FIGURE 4, showing an article, such as adolls head, formed in accordance with an alternate or modified method ofthe instant invention;

FIGURE 6 is a perspective view, with parts broken away to show internalconstruction, showing an article, such as a dolls head, having animatormeans connected to a soft, flexible portion thereof in accordance withthe method of the instant invention;

FIGURE 7 is an enlarged, partial, cross-sectional view taken along lines7-7 of FIGURE 6;

FIGURE 8 is an enlarged perspective view of a connector means which maybe embedded in the dolls head of FIGURE 6 in accordance with the presentinvention for connecting the animator means to the soft, flexibleportion of the dolls head;

FIGURE 9 is a front elevational view of an apparatus of the presentinvention which may be used for connecting the connector means of FIGURE8 to the soft, flexible portion of a dolls head, as shown in FIGURE 6;

FIGURE 10 is a rear elevational view of the apparatus of FIGURE 9showing the relative positions of certain parts thereof during theinstallation of the connector means of FIGURE 8 in the dolls head ofFIGURE 6;

FIGURE 11 is a front elevational view of the apparatus of FIGURE 9showing the relative positions of certain parts thereof during a laterstage of the installation of the connector means;

FIGURE 12 is an enlarged, partial elevational view of the connectormeans carrying and positioning arm forming a part of the apparatus ofFIGURE 9;

FIGURE 13 is an enlarged plan view of the arm shown in FIGURE 12;

FIGURE 14 is a cross-sectional view taken along line 14-14 of FIGURE 12;

FIGURE 15 is a cross-sectional view similar to FIG- URE 14 showing therelative positions of the parts shown in FIGURE 14 at a later stage inthe operation of the apparatus of the present invention;

FIGURE 16 is a wiring diagram of the electrical circuit employed in theapparatus of FIGURE 9;

FIGURE 17 is a flow diagram of the hydraulic circuit employed in theapparatus of FIGURE 9; and

FIGURE 18 is a schematic view of a vacuum pump and related equipmentused in connection with the apparatus of FIGURE 9.

In accordance with a preferred or exemplary method of the instantinvention for molding a hollow plastic article, there is illustrated inFIGURE 1 a slush-type mold 10 which may be of any suitable constructionand may be formed of any suitable material, such as electroformedcopper. The mold 10 comprises a hollow interior or cavity 12, preferablyhaving a nickel surface, but not limited thereto, and having apredetermined shape; for example, in the form of a dolls head or otherarticle to be molded therein. The mold 10 preferably is provided with ahorn-shaped, reduced end 14 in ordter to facilitate the filling andemptying thereof with a material to be molded.

Pursuant to the instant method, the mold 10 is first placed in aposition wherein the reduced end 14 faces upwardly, as shown in FIGURE1, and is filled with a first liquified plastic material 16 to be moldedtherein. The plastic material 16 may comprise a vinyl plastisol, such asa polyvinyl chloride resin, in combination with a suitable vinylplasticizer, as will be more specifically described hereinafter, or maycomprise other suitable thermoplastic materials.

After the filling of the mold 10 with the first plastic material 16, themold is placed in a hot oil or other type bath 18 within a tank 20 (seeFIGURE 1), and is heated therein for a predetermined time period, thebath being maintained at a temperature which is sufliciently high toeffect an initial cure of the portion of the material 16 in engagementwith the surface of the cavity 12. It is noted that the mold may beheated in any manner other than by immersion in a hot liquid bath,without departing from the scope of the present invention.

Referring now to FIGURE 2, after the mold 10 has been disposed in theoil bath 18 for the predetermined time period, it is removed from thebath and drained off the mold material 16 to leave a first unset, jelledlayer of the mold material 16 on the interior 12 of the mold 10, whichdefines a hollow dolls head H of substantially uniform thickness.

In order to provide the finally formed and cured dolls head H with arelatively thin and flexible face portion, but with a predeterminedportion, such as the upper and rear portion of the head, which is harderand less flexible than the face portion, the mold 10 thereafter istilted to a predetermined position, as shown in FIGURE 3, while theplastic layer 16 therein is still in a jelled condition. In thisposition, the mold is partially filled with a second liquified plasticmaterial 22 and is so oriented that the plastic material covers only theportion of the first plastic layer 16 defining the predetermined upperand rear portion of the dolls head H, which portion is intended to befinally formed in a harder and less flexible state than the face portionof the head. The second plastic material 22 may be substantially thesame as the first material 16, or may be of any other suitable type ofthermoplastic material. Preferably, the plastic material 22 is a vinylplastisol comprising a polyvinyl chloride resin and a vinyl plasticizerof the same type as those used in the first plastic material 16, as willbe more specifically described hereinafter, with the amount of theplasticizer being reduced on the second plastic material 22, so that thelatter will be harder than the first plastic material 16. It is notedthat, in accordance with this step of the instant method, the mold 10could be filled or oriented either before or after it is partiallyfilled with the second plastic material 22.

As further shown in FIGURE 3, the oriented mold 10, with thepredetermined portion of the second liquified plastic material 22therein, is inserted into a second liquid bath 24 wi;hin a tank 26 orotherwise heated to a predetermined temperature. The mold 10 ismaintained in the liquid bath 24 for a predetermined time period, whichis sufficient to partially cure a layer of the second material 22 inengagement with the jelled layer of the first plastic material 16therein. The mold may be tilted or oriented during heating in the bathor by other means in order to distribute the second plastic material 22over the predetermined area and to achieve various predeterminedthicknesses within that area.

The mold 10 thereafter is emptied of the liquified portion of the secondplastic material 22 to leave a jelled layer thereof on the predeterminedupper and rear head portion of the first jelled layer 16. Finally, themold 10 is again placed in a hot liquid bath (not shown) or otherwiseheated to a predetermined temperature, and for a predetermined timeperiod to finally cure and fuse the jelled layer 16 of the first plasticmaterial and the jelled layer 22 of the second plastic material coveringthe predetermined portion of the first layer.

After this final curing and fusing step, the mold is cooled to roomtemperature in any suitable or conventional manner and the finallyformed dolls head H is removed therefrom. The finally formed dolls headH is shown in FIGURE 4, wherein it will be readily seen that it isprovided with a front face portion formed of the layer 16 of the firstplastic material, and an upper and rear head portion which is formed ofthe fused layers of both the first plastic material 16 and the second,harder plastic material 22. The dolls head H, therefore, comprises aface portion that is thinner and more flexible than the predeterminedupper and rear head portion.

Such a doll head construction is highly desirable in that it provides ahollow head which is sufliciently firm to retain its general preformedshape, even though subjected to considerable distortion by a childplaying with it. Furthermore, since the face portion of the doll head ismore flexible than the balance of the head, it is capable of moreclosely simulating the features of a human being. This type of doll headconstruction is especially useful with talking-type dolls or toys,wherein it is important that the face portion of the head be relativelysoft and flexible so that it can be easily manipulated to closelysimulate the talking or sound-producing movement and features of theface of a human being or an animal.

As a specific example of the preferred method of the instant invention,the first plastic material 16 preferably has a hardness of approximately30 on the Shore durometer A scale, and comprises, by weight, 100 partsof a polyvinyl chloride resin such as; 150 parts of a vinyl plasticizer,such as dioctyl phthalate, diisodecyl adepate, or ditridecyl phtholate;parts of a stabilizing epoxy type plasticizer; 3 to 5 parts of a heatstabilizer; and 1 to 5 parts of a suitable coloring paste. The plasticmaterial 16 may be prepared by dispersing finely divided polyvinyl resinpowder in a liquid plasticizer to form a creamy liquid.

The initial cure of the plastic material 16 in the mold 10, when thelatter is immersed in the hot liquid bath 18, as shown in FIGURE 1, iseffected by maintaining the mold within the bath for approximately 1minute and 30 seconds, with the bath at a temperature of approximately400 F. The second partial cure of the jelled layer 16 and the liquifiedplastic material 22 within the mold 10, as shown in FIGURE 3, iseffected by maintaining the mold for approximately 45 seconds within thehot liquid bath 24, the latter being at a temperature of approximately400 F.

The second plastic material 22, as a specific example, has the samecomposition as that specified above for the first plastic material 16,with the sole exception that, in the second material 22, the parts ofthe vinyl plasticizer are reduced from 150 to 40 parts, therebyproviding the second material 22 with a hardness that measuresapproximately 90 on the Shore A scale. It is obvious that by furtherreducing the plasticizer level in the second material 22, it may be madeeven harder. A harder plastic material, however, will require a longercure time.

The final cure and fusing of the jelled layers 16 and 22 of the firstand second plastic materials, respectively, is effected by maintainingthe mold 10 for approximately 3 minutes in a hot liquid bath atapproximately 400 F.

FIGURE 5 illustrates an alternate from of head H, which is provided witha face portion 116 that is thinner and more flexible than the upper andrear head portion 116 in a manner similar to that of the head H. Thehead H differs from the head H, in that the former is formed entirely ofthe same plastic material composition.

The doll head H of FIGURE 5 may be formed in accordance with analternate method of the instant invention. In this alternate method, theplastic material 30 is poured in liquid form into a slush-type mold andinitially heat-cured in the same manner as that disclosed in FIGURE 1.Thereafter, however the mold is only partially drained of the liquifiedplastic material 30, and oriented in a manner similar to that shown inFIGURE 3, so that the remaining plastic material 30 is in engagementwith only a predetermined portion of the mold, namely, the portiondefining the upper and rear portion of the doll head. This partialdraining of the mold leaves a jelled layer of the plastic material 30over the portion of the mold defining the face portion of the doll head,in a manner similar to that shown in FIGURE 3 in relation to thepreferred method of this invention.

Thereafter, the mold is drained of the remaining liquified plasticmaterial 30, again heated to finally cure and fuse the material, andthen cooled in the same manner as that described above with respect tothe preferred method, to form the head H of FIGURE 5 wherein the faceportion 32 is thinner and more flexible than the upper and rear headportion 34.

Referring now more in particular to FIGURES 6-8, a figure toy 40 isshown herein for purposes of illustration, but not of limitation, asconstituting a hand puppet having a dolls head 42 and a body portion 44.The body portion 44 includes a cape 46 adapted to hide the hand of auser of the toy 40 and connected to the head 42 by an animator means 48of the type disclosed in copending application Ser. No. 544,441, filedApr. 22, 1966.

The doll head 42 may be made by any suitable method,

such as that heretofor described in connection with FIG- URES l-5, andincludes a soft, flexible face portion 50 made from a suitableelastomeric material which may be softened and resolidified, such as theplastisol material heretofor described in connection with FIGURES 1-5.The face 50 includes a mouth 52, a nose 54 and a pair of checks, such asthe one shown at 56. The mouth 52 may be molded with the normally-open,pleasant expression shown, if desired, and includes an upper lip 58 anda lower lip 60 which are joined together by an inwardlyextending member62.

The head 42 also includes a neck portion 64 which may be connected tothe animator means 48 within the open top portion 66 of the cape 44. Thehead 42 also includes an upper head portion 68 and a rear head portion70 both of which may be made in accordance with conventional methods,or, alternatively, in accordance with the method of the instantinvention described in connection with FIGURES 1-5.

The soft, flexible face portion may be animated by a suitable facialanimator 72 which is shown herein for purposes of illustration, but notof limitation, as comprising the facial animator shown and described indetail in said copending application. The facial animator 72 may beconnected to the soft, flexible face portion 50 by the method of thepresent invention using the apparatus shown in FIGURES 9-15 to install aconnector means 74 of the type shown and described in detail in saidcopending application. The connector means 74 includes an upper-lipconnector 76 and a lower-lip connector 78. The lip connectors 76, 78each include an embedable portion, in the form of a bight portion 80,and a connector portion, in the form of a pair of parallel, spaced-apartarms 82. The bight portions 80 are embedded in and adhered to associatedlips 58, 60 in accordance with the method of the present invention usingthe apparatus of the present invention to soften and resolidify the lips58, 60 under the embedable portion. This may be done by pressure aloneor by heating the connectors 76 and 78 sufficiently to heatsoften thematerial forming the lips 58, 60 while supplying sufficient pressure toan associated bight portion 80 to cause it to sink into the softenedmaterial to a suitable depth within an associated lip 58, 60, as will behereinafter described in detail. The lips 58, 60 may then be treated bycooling, or the like, to cause the material to resolidify and adhere tothe embedable portion.

Referring now more in particular to FIGURES 9-16, an apparatus of thepresent invention, generally designated 90, includes a doll-headpositioning member 92, a connector-means heating and positioning means94 and a positioning-means actuator means 96 all of which are mounted ona base member 98.

The posiioning member 92 includes a matrix 100 to which a pair of angleirons 102, 104 are aifixed for supporting the matrix 100 at apredetermined elevation above the base member 98 on externally threadedposts 106. This elevation may be determined by adjusting a plurality ofinternally threaded nuts 108 which threadedly engage an associated post106 below an associated angle iron 102, 104, thereby providing anadjustable support for the matrix 100. A second plurality of nuts 110thread edly engage associated posts 106 above associated angle irons102, 104 for securing the matrix 100 against upward movement thereon.The matrix 100 includes an upper surface 112 which is hollowed out toconform in shape and size to the external configuration of the face 50including a first recess 114 for receiving the nose 54, a second recess116 for receiving the upper lip 58 and a third recess 118 for receivingthe lower lip 60. A first small-diameter passageway 120 is provided inthe matrix 100 in fluid communication with the cavity 116 and a secondsmall-diameter passageway 122 is provided in the matrix 100 in fluidcommunication with the cavity 118. The passageways 120 and 122 bothcommunicate with a large-diameter passageway 124 which is also providedin the matrix 100 and which includes an internally threaded portion 126which receives an externally threaded nipple 128 for connecting thepassageway 124 to a conduit 130 by threadedly engaging the nipple 128with an internally threaded nut 132. The conduit 130 may be connected toan exhaust pump, shown schematically at 420 in FIGURE 18, for exhaustingthe passageways 120 and 122 so that the lips 58 and 60 will firmly seatin their associated cavities 116 and 118, thereby assuring uniformly inthe depth of penetration of the lips 58 and 60 by the bight portion 80,in a manner to be hereinafter described.

The heating and positioning means 94 includes a base plate 134 which isprovided with a pair of ways 136, 138 slidably receiving a carriage 140which is reciprocated by the actuator means 96. The carriage 140includes a leading edge 142 which is provided with an adjustable stopmember 144, a trailing edge 146 which is provided with an aperture 148and an apex portion 150 which is provided with an aperture 152.

The carriage 140 is connected to the actuator means 96 by a clevis 154having a first end 156 connected to the edge 146 by a pin 158 whichengages the aperture 148 and a second end 160 which is connected to theend 162 of a piston rod 164 reciprocably mounted in a hydraulic cylinder166 forming a part of the actuator means 96. The cylinder 166 includesan upstream end 168 which is connected to a source of fluid underpressure by a conduit 170 and a downwstream end 172 which is connectedto a source of fluid under pressure by a conduit 174. When fluid underpressure is admitted to the cylinder 166 through the conduit 170, thepiston rod 164 moves in the direction of arrow 175 (FIGURES and 11) andmoves in the direction of arrow 178 when fluid is admitted to thecylinder 166 through the conduit 174.

The connector means 74 are positioned and heated by an arm 180 which isswingably connected to the apex portion 150 of the carriage 140 by a pin182 engaged in the aperture 152 and carried by the arm 180 intermediateits first end 184 and its second end 186. The end 186 also carries a pin188 which rides in a cam slot 190 provided in a cam assembly 192 forswinging the arm 180 about pin 182 from the position shown in FIGURE 9to a substantially horizontal position during movement of the carriage140 from the position shown in FIGURE 9 to the position shown in FIGURE11 where the stop member 144 engages a fixed abutment 194. The cam slot190 includes an upwardly and forwardly sloping leg 196, which coactswith the pin 188 causing the arm 180 to pivot to its substantiallyhorizontal position, and a substantiall horizontal leg 198, which coactswith the pin 188 to maintain the arm 180 in its substantially horizontalposition during travel of the carriage 140 toward the matrix 100. Thistravel causes the end 184 of arm 180 to enter the head 42 forpositioning the connector means 74 superjaccnt associated lips 58 and 60when the stop member 144 strikes abutment 194. At this time, the cam 192is caused to swing in a clockwise direction, as viewed in FIGURE 11,about its pivot 200 which connects its end 202 to a fixed supportingplate 204 under the influence of a spring 206. The spring 206 has an end208 connected to a fixed support 210 and an end 212 affixed to the otherend 214 of the cam 192. The spring 206 is prevented from swinging thecam 192 about pivot 200 before the connector means 74 are positionedsuperjacent their associated lips 58 and 60 by a holding means 216 whichis reciprocably mounted on the base plate 134 and which carries a plate218 having a shaped opening 220 provided therein. The cam 192 carries apin 222 which is restrained by the plate 213 when the holding means 216is in a lowered position, as shown in FIGURE 9. However, when the stopmember 144 strikes the abutment 194, the holding means 216 is elevatedto the position shown in FIGURE 11 where the pin 222 no longer engagesthe plate 218 so that the spring 206 is free to swing the cam 192 in aclockwise direction, as viewed in FIGURE 11.

The amount of clockwise swinging of the arm 180 is controlled by a stopmember 224 provided thereon near the end 184 for engagement with anadjustable stop member 226 provided on the abutment 194.

The end 184 of the arm includes a dielectric core 228 for insulating afirst current-carrying finger 230 from a second current-carrying finger232 (FIGURE 13). The fingers 230 and 232 are each swingably connected tothe core 228 by vertical posts 234 and insulated bushings 236 forswinging movement between the solid line and broken line positions shownin FIGURE 13 to facilitate installing and removing the connector means74. Such swinging movement is performed by a finger-swinging apparatus,which is generally designated 238 in FIGURES 10 and 12. The apparatus238 includes a hydraulic actuator 240 having a hydraulic cylinder 2 42and a piston rod 244. The piston rod 244 carries a clevis 246 which isconnected to an actuating lever 248 by a pin 250. A pivot pin 252pivotally connects the lever 248 to a plate 254 which is carried by thearm 180 for positioning an apparatus 238 adjacent each finger 230, 232,as shown for the finger 232 in FIGURE 12. Each lever 248 includes abifurcated end 256 which straddles a dielectric bushing 258 carried byan arm 260 extending from an associated finger 230, 232 for swinging anassociated finger about an associated post 234 when an associated lever248 is pivoted by an associated piston rod 244. The fingers 230, 232 maybe swung to their broken line, FIGURE 13 positions by moving anassociated piston rod 244 in the direction of arrow 262 (FIGURE 12)swinging the end 256 of lever 248 rearwardly in the direction of arrow264. This swings an associated end 256 to its broken line. FIGURE 13position causing an associated arm 260 to swing an associated finger230, 232 to its FIGURE 13 broken line position. The fingers 230, 232 maythen be swung to their FIGURE 13 solid line positions by moving thepiston rod 244 reversely in the direction of arrow 266. The piston rod244 is moved in the direction of arrow 262 by admitting a fluid underpressure into the upstream end 268 of an associated piston 242 throughan associated conduit 270. The piston rod 244 may be moved in thedirection of arrow 266 by admitting a fluid under pressure into thedownstream end 272 of an associated piston 242 through an associatedconduit 274.

Electric current for resistance-heating the connector means 74 issupplied thereto through the fingers 230 and 232 by a transformer 276which is attached to the arm 180. The transformer 276 may comprise awelding transformer having a conventional primary winding, not shown,which may be connected to a suitable source of house current through avariable resistor, shown schematically at 278 in FIGURE 16, by a pair ofleads 280, 282. The primary winding (not shown) of the transformer 276is connected by a first lead 284 to the finger 232 and by a second lead286 to a finger 230 for supplying electrical current having a rating ofapproximately /25 volts and 70200 amps to the connector means 74.

The output from the transformer 27 6 should be capable of heating theconnector means 74 to a suitable temperature for melting the softplastic material in the lips 58 and 60 sufficiently quickly that theconnector means 74 may be installed on a mass-production basis whilecontrolling the temperature in such a manner that the plastisoldissipates the heat as the bight portion 80 of the connector means 74sinks therein due to the pressure applied to the arm 180 by the spring206. It will, of course, be apparent to those skilled in the art thatthe parameters necessary to accomplish this result will depend, in part,on the physical characteristics and dimensions of the connector means74. For example, it has been found that a fifteen gauge (0.0346 dia. to0.0344" dia.) steel music wire having a 1010-1060 carbon range andhaving a length of approximately 1.75 inches may be satisfactorilyheated by subjecting it to amps of current at 3 volts for 4 secondswhile pressing the connector means 74 into engagement with the softmaterial with approximately 2-3 pounds of pressure. The bight portions80 of the connector means 74 are preferably placed in contact with thesoft material before heat is applied to the connector means 74 so thatthe bight portions 80 will melt the material and sink thereinto beforethe connector means 74 becomes oxidized due to exposure to air while ina heated condition. Such oxidizing of the connector means 74 results inoxide being introduced into the soft material and forming an unbondablesurface. However, when the connector means 74 is not oxidized, thematerial in which the bight portion becomes embedded adheres theretoupon re-solidifying.

It was also found that a connector means 74 having these same physicalcharacteristics and dimensions could be satisfactorily embedded in thesoft plastisol by applying 70 amps at 3 volts for approximately l5seconds while subjecting the connector means 74 to a few ounces ofpressure. When a pound force was used, it was found that the connectormeans 74 could be installed in /2 second by subjecting it to 300 amps at1 /2 volts.

The portion of the dielectric core 228 which is engaged by the connectormeans 74 is protected from excessive wear by a pair of wear plates 228a.

The plate 218 is caused to reciprocate by an actuator means 288 whichincludes a hydraulic cylinder 290' and a piston rod 292. The piston rod292 is connected to the plate 216 by a cle'vis 294 which is pinned to adepending tang 29 6 by a pin 298. The piston rod 292 may be moved toraise the plate 216 by admitting hydraulic fluid under pressure to thecylinder 290 through a conduit 300 and is moved in the oppositedirection to lower the plate 216 by admitting hydraulic fluid underpressure to a conduit 302. Downward travel of the plate 216 actuates animpulse switch 304 which is connected to the plate 134 subjacent theplate 216 by a plate 305.

A normally-open switch 306 is mounted on the abutment 194 in such amanner that an actuating rod 308 for the switch 306 extends toward thecarriage 140* for contact thereby as the carriage 140 approaches theabutment 194.

The control means for controlling the operation of the apparatus 90 areshown schematically in FIGURES 16-l8. The electrical portion of thecontrol means, generally designated 310, is connected to an outsideelectrical power source by a pair of headers 312, 3 14 through switchblades 316, 318, respectively. A header 320 is connected to the switchblade 316 and a header 322 is connected to the switch blade 318 forsupplying electrical current to the various components of the controlmeans 310. These components include a first solenoid 324 which isconnected to the header 322 by a lead 326 and to a normally-open switch328 by a lead 330. The switch 328 is connected by a lead 332 to a switch334 which, in turn, is connected to the header 3 20 by a lead 336. Whenenergized, the solenoid 324 actuates a 4-way hydraulic valve 338 in sucha manner that hydraulic fluid under pressure flows through conduit 170into end 168 of cylinder 166 moving piston rod 164 in the direction ofarrow 176.

The control means 310 also includes a double-pole, single throw, relay340 which is connected to the header 322 by a lead 342 and to the switch306 by a lead 344. The switch 306 is, in turn, connected to the header320 by a lead 346. The relay 340 includes a first electrical contact 348which is connected to the header 320 by a lead 350 and to an electronictimer 352 by a lead 354. The timer 352 is connected to the header 322 bya lead 356 and includes an electrical contact 358 which is connected bya lead 360 to a second electronic timer 362 and to a second solenoid 363both of which are connected to the header 322 by leads 364 and 366,respectively. The relay 340 also includes an electrical contact 368which is connected by a lead 370 to a third electronic timer 372. Thetimer 372 is connected to the header 320 by a lead 374, to the header322 by a lead 376 and includes an electrical contact 378. The contact378 is connected by a lead 380 to a conductor 382 which, in turn, isconnected to the resistor 278, a third solenoid 384 and a fourthsolenoid 386. The solenoids 384 and 386 are connected by leads 388 and390, respectively, to the header 322.

The timer 362 includes an electrical contact 392 which is connected by alead 394 to the header 320 and by a lead 396 to a fifth solenoid 398which, in turn, is connected by a lead 400 to the header 322.

The impulse switch 304 forms part of the control means 310, is connectedby a lead 402 to the header 320 and by a lead 404 to a sixth solenoid406 switch, in turn, is connected by a lead 408 to the header 322.

The second solenoid 363 is connected to a 4-way, solenoid-operated,spring return hydraulic valve 410 which is biased to a first position bya spring 412. In the first position, the valve 410 permits the flow offluid under pressure through conduit 270 into cylinder 240 causingpiston rod 244 to move in the direction of arrow 266. Actuation of thesecond solenoid 363 overcomes the biasing spring 412 to position thevalve 410 in such a manner that fluid under pressure flows throughconduit 274 into cylinder 242 to move piston rod 244 in the direction ofarrow 272.

The third solenoid 384 and the fifth solenoid 398 are connected to a4-way, solenoid-operated hydraulic valve 414 which is connected to thehydraulic cylinder 290 by the conduits 300 and 302. When the solenoid384 is actuated, hydraulic fluid under pressure flows through theconduit 302 into the cylinder 290 forcing the piston rod 292 downwardlyso that plate 218 engages pin 222 returning cam 192 to its horizontalposition. When the solenoid 308 is actuated, the valve 414 is positionedin such a manner that hydraulic fluid under pressure flows through theconduit 300 into the cylinder 290 for moving the piston rod 292 upwardlyto bring the plate 218 out of engagement with the pin 222 so that thespring 206 is free to swing the end 184 of arm 180 toward the lips 58and 60.

The sixth solenoid 406 is connected to the valve 338 and may beenergized to position the valve 338 in such a manner that hydraulicfluid under pressure is free to flow through the conduit 174 into theend 172 of cylinder 166 iausing piston rod 164 to move in the directionof arrow The fourth solenoid 386 is connected to a 3-waysolenoid-operated, spring-return air valve 416 which is biased to afirst position by a spring 418. When energized, the solenoid 386overcomes the bias of spring 418 positioning the valve 416 in such amanner that air is exhausted from the matrix through conduit 130. Thisair is exhausted by a vacuum pump 420 which is connected to the valve416 through a tank 422 by conduits 424 and 426.

Hydraulic fluid for pressurizing the cylinders 166, 240 and 290 issupplied thereto through a header 428, a first branch line 430, which isconnected to the valve 338, a second branch line 432, which is connectedto the valve 414, and a third branch line 434 which is connected to thevalve 410.

A few examples of the method of the present invention are set forthhereinafter as follows:

EXAMPLE 1 A toy figure represented by the hollow head 42 having a soft,thermoplastic plastisol portion represented by the lips 58 and 60 wasplaced in the matrix 100 with the lips seated in the cavities 116 and118 when the apparatus 90 IS in the operating position shown in FIGURE 9with the arm extending substantially vertically.

A pair of connector means 74 were then inserted in the end 184 of arm180 between the fingers 230 and 232 with the arms 82 of the connectormeans 74 frictionally engaging the metal plates 228a, as shown in FIGURE15 for one connector means 74.

The switch blades 316 and 318 were then closed energizing the controlmeans 310, whereupon the switch blades 328 and 334 were closedcompleting a circuit to solenoid 324. The solenoid 324 positioned valve338 in such a manner that hydraulic fluid in header 428 flowed throughbranch line 430, valve 338, conduit 170 and into cylinder 166. Thisfluid forced the piston rod 164 in the direction of arrow 176 movingcarriage 140 toward abutment 194. During this movement, pin 188 on arm180 travel-ed up cam slot 190 causing arm 180 to swing counterclockwise,as viewed in FIGURE 10, toward a horizontal position. When the pin 188reached leg 198 of cam slot 190, the arm 180 was lying in asubstantially horizontal plane so that the end 184 could enter the openneck portion 64 of the head 42 as the carriage continued moving towardthe abutment 194. This movement of carriage 140 was then arrested bystop means 144 engaging abutment 194 at which time the carriage closedswitch 306 while the connector means 74 stopped superjacent associatedlips 58 and 60.

The closing of switch 306 energized the relay 340 cls ing the contacts348 and 368 to complete circuits to the timers 352 and 372,respectively. This energized the timer 372 closing its contacts 378 fora predetermined time within a range of A to 20 seconds, which waspreviously programmed into the timer 372, Closing contacts 378 completea circuit to the solenoids 384 and 386 and to the transformer 276energizing them. The transformer 276 supplied current to the connectormeans 74 within the range previously mentioned heating the connectormeans to a predetermined temperature suflicient to melt thethermoplastic material in the lips 58 and 60. Simultaneously thesolenoid 384 positioned valve 414 in such a manner that fluid underpressure in header 428 flowed through branch line 432, valve 414,conduit 300 and into cylinder 290 causing piston rod 292 to moveupwardly releasing plate 218 from engagement with pin 222. The spring206 then swung arm 180 about pivot pin 152 in such a manner that theconnector means 74 engaged the lips 58 and 60. Meanwhile, the solenoid386 had positioned valve 416 in such a manner that vacuum pump 420 waseffective to evacuate the matrix 100 through conduit 130, valve 416,conduit 426, tank 422 and conduit 424. This firmly seated the lips 58and 60 in their associated cavities 116 and 118.

The force in spring 206 applied approximately 1-3 pounds of pressure tothe connector means 74 causing them to melt the plastic material in thelips 58 and 60 as soon as they became heated. This caused the bightportions 80 to become embedded in the material to a depth determined bythe stops 224 and 226. The predetermined time set in the timer 372 thenelapsed and the contacts 378 opened deenergizing the solenoid 384 and386 and the transformer 276. In this example, the transformer supplied150 amps at 3 volts and the timer 372 maintained the transformer 276energized for approximately 4 seconds with a force of approximately 3pounds being applied to the connector means 74.

Energization of the timer 352 permitted the contact 358 therein to beclosed after the elapse of a predetermined time programmed into thetimer 352. This time is preferably just sufficient to energize solenoid363 and 362 shortly after the transformer 272 is de-energized.Energization of the solenoid 363 positions valve 410 in such a mannerthat fluid under pressure in header 428 flows through the branch line434 into valve 410 and through conduit 470 into cylinder 240.This-causes the piston rod 244 to move in the direction of arrow-262swinging lever 248 about pin 252 in such a manner that the fingers 230and 232 are swung to their FIGURE 13 broken line posi tions forreleasing the connector means 74, as shown in FIGURE 13.

Energization of the timer 362 causes its contact 392 to close after theelapse of the predetermined time programmed into the timer which, inthis specific example, was 4% seconds. The closing of contact 392completed the circuit through solenoid 398 which, in turn, positionedvalve 414 in such a manner that fluid in header 428 flowed throughbranch line 432, valve 414, conduit 302 and cylinder 390 causing pistonrod 292 to move downwardly bringing plate 218 back into engagement withpin 220 for swinging arm 180 counterclockwise, as viewed in FIG- URE 9,to a substantially horizontal position so that it may be withdrawn fromthe head 42. As plate 218 moved downwardly, the member 216 engaged theimpulse switch 304 to energize solenoid 406 after the elapse of thepredetermined time set in the impuse switch 304 which, in this specificexample, is A second. This is sutficient time to permit the arm 180 toassume a substantially horizontal position and to permit the time set intimer 352 to elapse so that the solenoid 363 becomes deenergizedpermitting spring 412 to position valve 410 in such a manner thathydraulic fluid from header 428 flows through branch line 434, valve410, conduit 274 and cylinder 240 moving the piston rod 244 in thedirection of arrow 266 to close the fingers 230 and 232 so that the end184 will clear the neck opening 64 when the arm 180 is withdrawn fromthe head 42.

Energization of solenoid 406 positioned valve 338 in such a manner thatfluid in header 428 flowed through branch line 430, valve 338, conduit174 and cylinder 166 moving piston rod 164 in the direction of arrow 178to withdraw the carriage from its position against abutment means 194 sothat the carriage 140 and the arm 180 were returned to their FIGURE 9positions.

The head 42 was then removed from the matrix 100 with the connectormeans 74 extending from their associated lips 58, 60. The lips weretreated by cooling them to cause the material to resolidify and adhereto the connector means 74. The animator 72 was then connected to theconnector means 74 by engaging the arms 82 into operative associationtherewith, as shown in FIGURES 6 and 7. The head 42 was then connectedto the animating means 48 and the open end 66 of the cape 44 wasinserted over the neck portion 64 of the head portion 42 and securedthereto.

EXAMPLE 2 A figure toy was constructed in accordance with the steps ofExample 1 except that a head 16, made in accordance with the moldingsteps of the present invention, was employed to take advantage of itsthickened portion 22.

EXAMPLE 3 A figure toy was made in accordance with the steps of Example1 except that the connector means 74 were heated at 70 amps and 3 voltsfor 15 seconds and a spring pressure of approximately 4 ounces was used.

EXAMPLE 4 A figure toy was made in accordance with the steps of Example1 except that the connector means 74 were heated for approximately /2second at 2 volts and -200 amps while a 10 pound force was applied tothe connector means 74.

While the particular apparatus and method herein shown and described indetail are fully capable of attaining the objects and providing theadvantages hereinbefore stated, it is to be understood that they aremerely illustrative of the presently preferred embodiment of theinvention and that no limitations are intended to the details ofconstruction, design or method steps herein shown and described otherthan as defined in the appended claims.

What is claimed is:

1. A method of making an animated figure toy comprising the steps of:

(A) forming a figure toy having a predetermined shape, at least aportion of said toy being formed from a material which will soften andre-solidify, said forming including the steps of:

(I) forming a first layer of heated, gelled plastic material on theinner surface of a mold;

(II) forming a second layer of heated, gelled plastic material on apredetermined portion of said first layer on said inner mold surface;and

(III) curing said first and second layers to form a hardened, unitary,hollow article within said mold having a thickened portion correspondingto said second layer;

(B) pressing an animator connector means into engagement with saidsoftenable, re-solidifiable material;

(C) softening said softenable, re-solidifiable material under saidconnector means while maintaining said pressure for embedding a portionof said connector means in said softenable, re-solidifiable material;

(D) treating said softened material for adhering said material to saidembedded portion of said connector means; and

(E) connecting animator means to said connector means for moving saidportion of said toy to animate said toy upon actuation of said animatormeans.

2. A method of making an animated figure toy comprising the steps of:

forming a figure toy having a predetermined shape, at

least a portion of said toy being formed from a material which willsoften and re-solidify;

placing said material in a matrix conforming in shape to the shape ofsaid material;

seating said material in said matrix by evacuating said matrix;

placing an animator connector means in an electrical current-carryingfixture, said connector means comprising a U-shaped, wire clip having abight portion;

inserting said fixture into said toy with said connector means injuxtaposition to said material;

lowering said fixture to press said connector means into engagement withsaid material with a predetermined pressure;

passing current through said fixture and said connector means to heatsaid bight portion by electrical resistance heating for softening saidmaterial under said connector means while maintaining said pressure forembedding said heated bight portion in said material;

treating said softened material for adhering said material to saidembedded portion of said connector means; and

connecting animator means to said connector means for moving saidportion of said toy to animate said toy upon actuation of said animatormeans.

3. The method of claim 1 wherein said first layer is formed by fillingsaid mold with a'plastic material in liquid form and partially curing itin said mold.

4. The method of claim- 3 wherein said second layer is formed bymaintaining said mold partially filled with a plastic material whichcovers only said predetermined portion of said inner mold surface, andpartially curing said last mentioned plastic material in said mold.

5. The method of claim 4 wherein said second layer comprises a plasticmaterial which is harder than that of said first layer, to thereby forman article having predetermined portions of varying thickness andhardness.

6. The method of claim 4 wherein said plastic material comprises apolyvinyl chloride resin and a vinyl plasticizer.

References Cited UNITED STATES PATENTS 2,386,824 10/1945 Tinnerman264-271 X 2,525,272 10/1950 Rhoton 264-255 X 2,974,373 3/1961 Streed eta1. 264-255 X 3,035,309 5/1962 Bingham 264-255 3,100,254 8/1963 Perkins29-4975 3,320,344 5/1967 Slipp 264-255 3,345,227 10/ 1967 Park 264-271JOHN F. CAMPBELL, Primary Examiner.

P. M. COHEN, Assistant Examiner.

